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CONESTOGA COLLEGE
ROBOTICS AND INDUSTRIAL
AUTOMATION

[V]
TEAM VIKINGS

PROJECT DESIGN REPORT:

DOODAD CASE ASSEMBLER
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TABLE OF CONTENTS

TEAM MEMBERS………………………………………………………………..…………….2
TABLE OF CONTENTS…………………………………………………………………...…...3
PROJECT ABSTRACT………………........……………………………………………………5

1 THE PROJECT ..........................................................................................................................6

1.1 Project Statement ............................................................................................................... 6
1.2 Objectives And outcomes .................................................................................................. 6

2 METHODOLOGY .....................................................................................................................7
2.1 Analysis ............................................................................................................................. 7
2.2 Developement .................................................................................................................... 8
2.3 Testing ............................................................................................................................. 10

3 THE PROCESS.........................................................................................................................11
3.1 Gantt Chart (Updated) ..................................................................................................... 11
3.2 Team Meeting Documentation ........................................................................................ 12

4 THE DESIGN…………………………………………………………………………………13
4.1 System Layout ................................................................................................................. 13
4.2 Doodad Mechanical Design ............................................................................................. 14
4.3 Pneumatic Layout ............................................................................................................ 15
4.3.1 Parts Description ...................................................................................................... 15
4.3.2 Pneumatics 1
4.3.3 Pneumatics 2
4.3.4 Pneumatics 3
4.3.5 Pneumatics 4
4.4 Electrical Drawings ......................................................................................................... 19
4.5 PLC Logic ........................................................................................................................ 20
4.6 HMI Design ..................................................................................................................... 21
4.7 Robot Programming......................................................................................................... 27
4.8 Smart Motor Programming .............................................................................................. 31

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4.9 Vision System .................................................................................................................. 40

4.10 Process Flow Chart ........................................................................................................ 59
4.11 Cycle Time Calculation ................................................................................................. 60

5 OPERATOR MANUAL…..…………………………………………………………………61
5.1 Explanation Of Setup ....................................................................................................... 62
5.2 Step By Step Operating Procedure .................................................................................. 63
5.3 Troubleshooting ............................................................................................................... 63

6 CONCLUSION .........................................................................................................................65

7 POSSIBLE IMPROVEMENTS TO THE SYSTEM .............................................................66

8 FUTURE SCOPE ......................................................................................................................67

9 APPENDICES ...........................................................................................................................68
9.1 CX-Programmer Manual ................................................................................................. 68
9.2 CX-Designer Manual ....................................................................................................... 69
9.3 Cognex Manual ................................................................................................................ 70

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PROJECT ABSTRACT

The project involves the reverse-engineering of an already existing automated

work cell and reconfigure it to assemble Doodad Cases for G&G Automation. At the
end of the project period the work cell was able to properly align and assemble the
main two parts of a Doodad case as well as test it for errors or discrepancies. The
project also includes the design and fabrication (using rapid prototyping) of a
Doodad case which would conform to the all the specifications of the assembler’s
material handling equipment. The whole system was designed to be completely safe
for the operator and the machine alike and conforms to all the safety standards of the
company. The estimated time line for the project was 10 weeks which included
planning, research, mechanical design, programming (and reprogramming) and
documentation of the assembler.

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1. THE PROJECT

1.1 The Project Statement:

The project involves the reverse-engineering of an already existing automated work

cell and reconfigure it to assemble Doodad Cases for G&G Automation. All the
equipment and devices are integrated and automated to successfully obtain the
Doodad Case. All the safety aspects are taken into consideration and the project is
built with ease of use for the operator.

1.2 Objectives and Outcomes:

The objectives and outcomes of this project is as follows:-

 Develop an optimized mechanical design for a Doodad case and make

prototypes for the same

 Reverse engineer all electrical and pneumatic setup of the assembler and
document them for reference

 Program the PLC for optimized assembly of the error free product

 Program the Denso robot for correct pick and place operation

 Program all servo and smart motors to accomplish the required task

 Use the Cognex vision system for quality control

 Testing, troubleshooting and tweaking to attain the target production rate with
maximum efficiency

 Involve all safety aspects as required

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2. METHODOLOGY

1. Research and Analysis:

To identify all the information and requirement such as hardware and

software we required deep research of the components. The reason behind of doing
the research was to understand what exactly required to meet the project . We
started data collection and study about the components.

Data collection is a stage in any area of study. At this stage our team planned
about the projects resources, requirements and schedule to get more information in
this study. All the research and data collected from journals and research papers
gathered from the Internet. Within the data collection period we have given the
individual responsibility to carry on the research and finish the assigned work that
include designing or drawing, programming of PLC, HMI designing, Pneumatics,
working of a camera, LinMot and AcTech drives, Denso Robot programming.

I. Electrical study:
Connections were the main requirement of the project so that we can program
and design the control system. The project required different types of device
connections and panel connections. These connections were not easy enough
without any deep level of research and must be wired right way to make the
connections safe and secure. Our team first step was to understand the connections
of all the electrical components such as actuators, sensors and motors to the plc.
Just connecting wires to device terminals doesn’t solve the problem. We
researched about the correct way to connect.

II. Pneumatic study:

Our team researched about the particular technology used in and how it is
applied in our project there was a systematic study on the circuit and components
we want to study like pressure regulator and valves.

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III. Machine vision system:

Cognex camera is used in our project to inspect the part whether it is a good or
bad. It was a new approach camera just need to take a photo and it will scan it
according to what is our requirement (Pre values).

IV. Safety Analysis:

For the safety of the our team and the prevention of damage to the
robot itself and its environment we decided to study about the safety
precautions as if we are using it in real time. The necessary parameters has
been taken to prevent any sort of accident.

2. Development:

Our team focused on the analysis part so that we can proceed with an idea to
implement it while developing the project.

The project is being depended on extra in the testing process, for proper use
of time and research it is crucial that every team member involved has a good
understanding of the steps taken in the project. Our team focused on the analysis
part so that we can proceed with an idea to implement it while developing the
project. We have to be sure that every team member understands how the project is
built, maintained, executed.

The work was divided to achieve the goal so we come with the solution that we
will make algorithm for each divided work.

I. Programming the PLC:

 After the research has been done the next important thing was to find
out the input and output ports so that the connection and addresses
will be given to the programme.
 By analysing the connections, addresses was the main obstacle to be
figured and we figured it out by using analysis method and started
checking the programme repeatedly.

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II. Programming the Denso robot

 The connection and programming of the software was arrange in such
way that it should receive a message from the congnex camera
whether the part is good or bad.
 If the part is good put into the smart motor if bad put the part in bin
 Difficult to establish the connection using wincapIII and unexpected
movements of the robot we figured the problem is with the drive and
solved the problem researching about the driver.
III. HMI design
 The first step was to Setup the communication
 Selection of the proper version and screen size of the HMI
 Problem faced during the communication between HMI and PLC

IV. Cognex camera

 Camera detect the part and we need to feed thickness of the pattern of the
part and edge to edge distance in the system.
 Comparing the part by using the software InsightExplorer
 If the part is matched with the pre values then it is a good part if not matched
then bad part.
 The setup of cognex camera with the PLC was problematic and there was no
input modules to the vision camera. Cognex had inbuilt Input and Output
terminals it was very difficult to find input and output of the camera this is
solved by connecting directly to the plc and triggering each I/O to confirm
the addresses. Common I/O wires are connected to the 0Volts which was
important for triggering the input and output.
V. CAD design of parts and panel:
 We used SolidWorks to designing the part it was not so tricky we did the
designing part with a good precision so that the dimension should be exactly
what is required for the project.
 Used AutoCAD for schematic connections

VI. LinMot motor:

 Software used for programming the LinMot was LinMotTalk

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 Communication Setup was done to plc without any problem

 There was problem with the communication cable and to solve that problem
we made a custom cable.

VII. Design of Pneumatic circuit

 Pneumatic circuit was already built in the station we did a thorough research
on connection , distribution and important components of the circuit
 We design the circuit using Automation Studio.
VIII. Smart Motor
 Connecting smart motor with pc using Rs232 and programmed the smart
motor using SMIinterfece.
 The problem faced during the connection of the Smart motor when trying to
connect with the PLC.
 when plc is turning output on, it gives 24 volts to the corresponding output
port but we need 0volts in SMI input
 It was not connecting to the output card so we used 24volts relay

3. Evaluation:

On the basis of our technique for evaluation we used the analysis method,
which proved to be quite fruitful as it was a unique method of data collection and
experimentation/programming. We checked the programs by debugging it step by
step to perform the operation as required.

Our team was aware about the problems facing during the development of
the project so we used different ways to tackle the problems sometimes using trial
and error method. We checked each and every one problems and working of the
project which was assigned.

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3. THE PROCESS
3.1 Gantt Chart (Updated)
(Refer Gantt Chart)

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3.2 Team Meeting Documentation

TEAM DATE &

TOPICS DISCUSSED
MEETING TIME
1. Various safety features for the project discussed.
Safety guidelines for the project is prepared.
2. Dividing the projects into 3 stages has been discussed.
According to this discussion, project is divided into three
January-19-2015 stages.
1 3. Assigning tasks to team members has been discussed.
(12-1 PM)
4. Tasks have been assigned to the team members
5. Discussed about various software to be used in the
project.

1. Creating a database of IOs and parts numbers has been

discussed and making the database accessible to all users.
2. Discussed about the planning report evaluation.
February-2-2015 3. Discussed about troubleshooting the connections of
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(12-1 PM) DENSO Robot

1. Discussed about updating the database. Instructions to

include other details have been given.
2. Discussed about the problems encountered in the
February-16- vision system.
3
2015 (12-1 PM)

1. Discussed about HMI screens.

2.Checked the SMART motor programming
3.Checked the robot working method
March-9-2015
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(12-1 PM)

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March-23-2015 1. Discussed about the problem encountered in

(12-1 PM) downloading HMI to machine.

1. Discussed about various troubleshooting methods

March-30-2015
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(12-1 PM)

4.THE DESIGN
4.1 System Layout:
(Refer Drawings)

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4.2 Doodad Mechanical Design

(Refer Drawings)

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4.3 Pneumatics:
4.3.1 Pneumatics Parts descriptions:
 Devices and their description:

 Air Supply unit:

1. Soft Startup Valve

 Type - Double acting, single rod,

compact cylinder

 Model – NAV200-N02-5BZ

 Manufacturer - SMC

 Number of valves used – 1

 Port Size – 1/4

 Rated Coil Voltage: 24VDC

 Operating pressure range - 29 to 145psi

 Actuators:

1. Cylinders:

 Type - Double acting, single rod, compact cylinder

 Model – CDQ2A50-50DM

 Manufacturer - SMC

 Number of Cylinders used – 4

 Bore Size – 50mm

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 Standard stroke range *: 5 to 100

2. Grippers:

 Type: 2-Jaw Parallel Gripper

 Model – DPP-14M-15

 Manufacturer – DESTA.CO

 Number of grippers used – 2

 Stroke: 15.9mm

 Grip Force: 200N

 Cylinder Bore: 14.3mm

 Pressure Range: 50-100psi

 Pressure regulators:

 Type -Electro-Pneumatic Regulator

 Model – ITV2050-04N2L4

 Manufacturer - SMC

 Number of regulators used – 1

 Pressure range – 0.9MPa

 Power supply voltage – 24VDC

 Input signal – 4 to 20 mA

 Monitor output - Analog output 4 to 20mA

 Thread type – NPT

 Port size - ¼

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 Pressure display unit – PSI

 Precision regulators:

 Type –High Precision regulator

 Model – IR1010-N01

 Manufacturer - SMC

 Number of regulators used – 2

 Pressure range – 0.01 to 0.4 MPa

 Power supply voltage – 24VDC

 Input signal – 4 to 20 mA

 Max. supply pressure: 1.0 MPa

 Min. supply pressure: Set pressure + 0.05 MPa

 Port Size: 1/8

 Directional Valves:

 Type - Solenoid Valve

 Model – SY5320-5DZ-N7T

 Manufacturer – SMC

 Number of ports - 5

 Type of actuation– 3-position closed center

 Pilot type - Internal pilot

 Rated voltage – 24VDC

 Thread type - NPTF

 Port Size(A,B) - ø1/4"

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 Pressure switches:

 Type - High Precision Digital Pressure Switch

 Model – ISE40-01-62

 Manufacturer - SMC

 Number of regulators used – 2

 Rated Pressure range : –14.5 to 145.0 psi

 Power supply voltage – 12 to 24 VDC

 Analog output(Current) - 2.4 to 20 mA

 Withstand pressure – 218psi

 Switch output – PNP with max load current of 80 mA

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4.4 Electrical Drawings

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4.5 PLC Logic

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4.6 HMI Design

HMI SCREENS

SCREEN 1

 This screen will be appeared on the HMI when it starts.

 It enables the user to navigate to different screens.

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SCREEN 2

 This screen is created for the operator to carry out all the station functions.

 It contains bit lamps which indicate the current stage of the program.

 It has a fault reset button to reset all the faults occurred in the station.

 A button to trigger the ESTOP which shut off all the power to the station
instantly.

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SCREEN 3

 This is the maintenance screen which enables the user to manually operate
the devices.

 It has the status indicators for faults occurred in the station.

 It has navigate buttons to the remaining manual screens.

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SCREEN 4

 This is the management screen which contains the part count, cycle time and
fault count.

 This screen has navigation buttons to all the screen and it contains the
ESTOP and fault reset buttons.

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SCREEN 5

 This screen has manual mode operations for station 2.

 This screen is designed for the maintenance person.

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SCREEN 6

 This screen has manual mode operations for station 3, 4 and 5.

 This screen is designed for the maintenance person.

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4.7 Robot Programming

DENSO VE026A ROBOT

Robot Specifications:-

Item Specs

Model of Robot Unit VE026A

Number of axis 6 for Robot and 1 for gripper

Mounting Configuration Floor

Weight 550g

Position Repeatability High Accuracy Potentiometer

Power Supply AC100-240V 50-60Hz 1.5A

Robot’s task:-

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The robot is programmed to pick and place part from the turn table. It operates
under two scenarios. If the processed part is good the robot picks the part from the
turn table and places it on the smart motor, whereas if the part is bad then the robot
picks the part from the turn table and places puts it into the bin. The robot is
programmed using WINCAPS software.

Robot position coordinate table

Robot Program

'!TITLE "VIKINGS ROBOT PROGRAM"

'This program takes good/bad part from the turn table and either puts it in the bin
or on the top of smart motor depending on the part.

PROGRAM VE026A_DEMO

TAKEARM 'TAKE CONTROL OF ARM

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WAIT IO[0]=ON 'WAIT FOR THE SIGNAL FROM THE PLC TO START
ROBOT MOTION

Move P, @0 P1 'Move to P1 by PTP motion WHERE P1 IS THE HOME

POSITION

SPEED 50 'DEFINE ROBOT SPEED

IF IO[1] THEN 'If part is good then do the following steps

Move P, @0 P2 'Move to P2 by PTP motion where p2 is above rack position

DRIVEA(7, F2) 'FINGER OPEN

Move P, @0 P3 'Move to P3 by PTP motion where p3 is part pick position

DRIVEA(7, F1) 'FINGER CLOSE

Move P, @0 P5 'Move to P5 by PTP motion where p5 is above rack position

Move P, @0 P6 'Move to P6 by PTP motion where p6 is above smart motor

position

Move P, @0 P7 'Move to P7 by PTP motion where p7 is on smart motor position

DRIVEA(7, F2) 'FINGER OPEN

Move P, @0 P6 'Move to P6 by PTP motion

Move P, @0 P1 'Move to P1 by PTP motion WHERE P1 IS THE HOME

POSITION

ELSE 'if part is bad then do the following steps

Move P, @0 P2 'Move to P2 by PTP motion where p2 is above rack position

DRIVEA(7, F2) 'FINGER OPEN

Move P, @0 P3 'Move to P3 by PTP motion where p3 is part pick position

DRIVEA(7, F1) 'FINGER CLOSE

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Move P, @0 P5 'Move to P5 by PTP motion where p5 is above rack position

Move P, @0 P8 'Move to P8 by PTP motion where p8 is the bin position

DRIVEA(7, F2) 'FINGER OPEN

Move P, @0 P1 'Move to P1 by PTP motion WHERE P1 IS THE HOME

POSITION

ENDIF 'End of program

RESET IO[0] 'RESET IO

END 'END OF PROGRAM

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4.8 SMART MOTOR PROGRAMMING:

SMART MOTOR- SM23165D

Smart Motor is a highly programmable servo system integrating a motor, an

encoder, an amplifier, a controller, RS232/RS485 communication, and IOs.

TECHNICAL SPECIFICATION:

Continuous
Torque 2.50 in-lb; 40 oz-in; 0.28 N-m

Peak Torque 4.00 in-lb; 64 oz-in; 0.45 N-m

Nominal
Continuous
Power 181 Watt

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Weight 1.0 lb; 0.45 kg

No Load Speed 10,400 RPM

Continuous
Current @
Nominal Power 5.0 Amps

Voltage
Constance 4.45 V/kRPM

Winding
Resistance 1.0 ohms

Encoder
Resolutions 4,000 counts/Rev

Rotor Inertia 0.00099 oz-in-sec2; 0.699 10-5 Kg-m2

Shaft Diameter 0.250 in; 6.35 mm

Shaft, Radial
Load 7 lb; 3.18 kg

Shaft, Axial
Thrust Load 3 lb; 1.36 kg

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NEMA Frame
Size NEMA 23

Connector Type D-Style

DIMENSION DRAWING:

RS 232

RS-232 defines the connection between data terminal equipment (DTE) and data
circuit-terminating equipment (DCE). Data terminal equipment is any end user
device, such as a computer, that can be used to send data over a network. Data
circuit-terminating equipment is a device that provides the interface between the
DTE and the network, and is often a modem or terminal adapter. An RS-232-

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compatible interface was commonly used for computer serial communication

(COM) ports, which were originally intended for connecting the computer to a
modem. While the original RS232 standard specified 25-pin connections, many of
the pins were not used in practice, and a 9-pin connection was implemented on
most computers. Although the RS-232 port has now largely been super ceded by
USB for connecting peripheral devices to personal computers, it is still often
provided to enable the connection of legacy devices. The illustration below shows
the 25-pin and 9-pin DTE-to-DCE connections that would result if the EIA232
standard were strictly followed. The most commonly used signals are shown in
red.

RS-232 devices are either DTE or DCE devices. Computer terminals are usually
equipped with male connectors with DTE pin functions, while modems have
female connectors with DCE pin functions. Although the standard specifies twenty
different signal connections, most devices use only a few of these signals, enabling
the smaller 9-pin (DB9) connectors to be used. The more commonly used signals
are shown in the table below.

Commonly-used RS-232 signals

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Signal Description

TxD Transmitted Data - data transmitted from the DTE to the DCE

RxD Received Data - data transmitted from the DCE to the DTE

RTS Request To Send - set to 0 (asserted) by the DTE to prepare the DCE to
receive data

CTS Clear To Send - set to 0 (asserted) by the DCE to acknowledge RTS and
allow the DTE to transmit

DTR Data Terminal Ready - set to 0 (asserted) by the DTE to indicate that it is
ready to be connected

DSR Data Set Ready - set to 0 (asserted) by the DCE to indicate an active
connection

DCD Data Carrier Detect - set to 0 (asserted) by the DCE when a connection
has been established with a remote device

RI Ring Indicator - set to 0 (asserted) by the DCE when it detects a ring

signal from the telephone line

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PC-SMART MOTOR INTERFACE CONNECTIONS

Description:

 The smart motor is powered on a 24 VDC power supply from an

external source.

 The Smart motor is then connected to the personal computer using

an RS 232 network cable.

 Using the Smart Interface program a program is downloaded to the

smart motor.

 The output from Digital output card (2.09) is made to trigger at input
terminal (2) of the smart motor, which triggers the motion.

 The signal from output card is given to the motor using a 24 VDC
relay.

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SMART MOTOR PROGRAM:

EIGN(2)

EIGN(3)

ZS

MDS 'Using Sine Mode commutation

KP=3200 'Increase stiffness from default

KD=10200 'Increase damping from default

F 'Activate new tuning parameters

AMPS=100 'Lower current limit to 10%

VT=-150000 'Set maximum velocity

ADT=2500 'Set maximum acceleration

MV 'Set Velocity Mode

G 'Start motion

WHILE EA>-100 'Loop while position error is small

LOOP 'Loop back to WHILE

O=-100 'While pressed, declare home offset

S 'Abruptly stop trajectory

MP 'Switch to Position Mode

ADT=1500

VT=20000 'Set higher maximum velocity

PT=0 'Set target position to be home

G 'Start motion

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TWAIT 'Wait for motion to complete

AMPS=1000 'Restore current limit to maximum

EIGN(W,0) 'Disable hardware limits

ZS 'Clear faults

ADT=2500 'Set maximum acceleration

VT=1000000 'Set maximum velocity

MP 'Set Position Mode

ADT=1500

VT=300000 'Set higher maximum velocity

PT=74000 'Set target position to be home

G 'Start motion

C10 'Place a label

IF IN(0)==0 'When the ipnut 1 is true the following conditions

occurs

ADT=1500 'Set maximum acceleration

VT=300000 'Set maximum velocity

PT=0 'Set position

G 'Start motion

TWAIT 'Wait for move to complete

WAIT = 6000

ADT=1500 'Set maximum acceleration

VT=300000 'Set maximum velocity

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PT=74000 'Set position

G 'Start motion

TWAIT 'Wait for move to complete

ENDIF

GOTO(10) 'Loop back to label 10

END 'Obligatory END (never reached)

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4.9 VISION SYSTEM:

Introduction

The In-Sight 7000 series, IS 7200 821-0084-1R D vision system is used in this
project for the automatic extraction of information from digital images and to
perform different functions such as to locate and detect orientation, Measurement,
to check presence/ absence of the part and its inspection and error proofing. It is a
compact, network-ready, stand-alone machine vision system.

Need of Machine vision systems

 To reduce human error

 To avoid Operator variance

 Improve product quality

 Increase safety

Components of Machine vision systems

Cognex cameras are smart cameras and they have typically five components that
make up a machine vision system; they include

 Sensors/ Camera

 Light source

 Lens

 Hardware

 Vision processing Software

 Input/output Interfaces

 Data Communication

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The operating principle of vision systems can be explained as follows: there will be
a target to capture image. We shine light on it, the light reflects back and the
corresponding data related to image is collected. It is processed and measurements
are taken to make judgments like whether it is good or bad part and the output is sent
to robot, PLC or may be to some external control devices to make proper decisions
whether to proceed or reject the part.

In-Sight vision system has powerful vision tools and In-Sight Explorer software
interface. The smart vision tools have automatically select features, set parameters
and operate in real world conditions without adjustment.

Communications:
In-Sight I/O Expansion Modules

Breakout Cable (on unit itself):

• 1 high speed input (camera) trigger(White yellow)

• 2 high speed discrete outputs (Brown and White brown)

• 2 programmable LEDs (RED and Green)

• 1 serial with no RTS/CTS (not with Micro)

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The Input Configuration

The Power and I/O Breakout cable can be used to connect to a PNP-compatible
PLC output. Connect any general purpose input directly to the PLC output. As the
PLC output is sinking and the cognex input is sourcing.

The Power and I/O Breakout cable provides connections to an external power
supply, the acquisition trigger input, general-purpose inputs, high-speed outputs,
and RS-232 serial communications. The Power and I/O Breakout cable is not
terminated.

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The white-violet and black are connected to common 0V and the white-yellow
which is the input for Cognex is connected to the output slot of the PLC IO 3.15

The tag accusation trigger is used to trigger the camera for image.

Output Configuration

The Power and I/O Breakout cable can be used to connect to an NPN-compatible
PLC input. Connect any high-speed output directly to the PLC input. When
enabled, the output pulls the PLC input down to 1VDC or less.

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The Power and I/O Breakout cable provides connections to an external power
supply, the acquisition trigger input, general-purpose inputs, high-speed outputs,
and RS-232 serial communications. The Power and I/O Breakout cable is not
terminated.

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White-brown and brown are outputs .The green is connected to common along
with black 0V and the red is connected to 24V DC .The wire white-brown is for
detecting bad part and brown for detecting good part.

Tags used are for good part (PLC IO 1.14).

Hardware Installation

Connectors and indicators

Connectors

ENET Connector- It provides the Ethernet connection to external network devices.

LIGHT Connector- It connects to the external lighting source.

PWR Connector- connects the Power and I/O Breakout cable.

Ethernet cable
Light cable
Power and I/O
Breakout cable

Indicators

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INDICATOR FUNCTION

ENET LNK Solid green when a network connection is detected.

LED

ENET ACT Flashes green when there is network activity.

LED

PWR LED Solid green when power is applied.

USR1 LED Green when active. User-configurable using Discrete

Output Line 4.

USR2 LED Red when active. User-configurable using Discrete

Output Line 5.

Light Source

Unlike most vision systems, the In-Sight 7000 smart camera has the capability to
power and control specialized lighting directly and eliminating the need for
external power supplies.

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In-Sight Explorer Software Features

In-Sight Explorer 4.7.3 software interface is used for graphical controls such as
lights, data displays and entries, image analysis and processing in this project. It
includes an EasyBuilder view and a spreadsheet view
configuration.

EasyBuilder user interface

EasyBuilder software interface offers everything required

to easily set up reliable applications quickly, with no programming required.

Spreadsheet view

Spreadsheet view makes the user experience very simple

for maximum control over your optical inspection
applications. This configuration allows creation of
custom graphical user interfaces and access to
complex logic statements thereby allowing the
full control of vision applications.

In this project for the inspection of part and for

judgment we use most of the features in
EasyBuilder configuration rather than spreadsheet view. Round tripping feature is
also used by switching from EasyBuilder to Spreadsheet and vice-versa, i.e. the
Full spreadsheet is accessed using EasyBuilder and the EasyBuilder is built on
spreadsheet (runs on the background).

PROCEDURE

To configure an In-Sight vision system, In-Sight Explorer software must be

installed on a networked PC.

1. Log On to the Vision System. Open the In-Sight Explorer software. From
the Windows start menu, Select: All Programs > Cognex > In-Sight > In-
Sight Explorer 4.7.3

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2. The interface Easy Builder guides the user step by step through the
configuration of the image processing application. Mainly, four simple steps
complete the application setup:

Start - Connect your In-Sight vision system on network and set up the image to
inspect

Set up tools - Locate and inspect the part using a library of over 40 industry
proven vision tools.

Configure - Point-and-click setup for inputs, outputs, and communication to PLCs,

robots and HMIs.

Finish - Choose the images to record while inspecting, and put In-Sight vision
system online.

3. The image setup in the EasyBuilder interface is then organized and built in
Spreadsheet view.

Application Steps

1. Start

Get Connected

Before controlling the camera, we should log on to it. To

log on, find the camera in the Insight network pane and
double click it.

If camera is not on the list, click System > ‘Add Sensor/Device to network’

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‘Add Sensor/Device to network’ Dialog box appears and automatically detects

Insight sensors with invalid network settings on TCP/IP subnet and displays them
in a list.

Setup Image

Acquiring or Loading an image

Acquire/ Load image allows instantly acquires an

image from Trigger, Live video or to load images
from PC.

Trigger- is used to acquire a single image from the

vision system. Press the button.

Live video - click live video button to stream live

image without acquiring them. Press this button.

Load Images from PC - used to configure record and

playback settings for individual vision systems and emulators.

Triggered Image

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Live video

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In the ‘Edit Acquisition Settings’ Tab, the

brightness of the part is adjusting the value of
exposure. The exposure region is selected as
shown in the next page. The focus adjusted as
shown in next page.

Calibrating the Image to Real World Units

For In-Sight vision systems, calibration refers to the process of "mapping" the
image area by establishing a relationship between features in the image and known,
real-world measurement units. For that, select the calibration type and for the
figure shown below, ‘edge to edge’ calibration type is selected.

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The value is entered in millimeters and it is calibrated by selecting the desired

edges as shown in the figure below.

Thickness of the
part for
inspection

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2. Setup Tools

Locate Part

There are different location tools in the ‘Add Tool’ Palette as shown above. To add
a Location Tool to the job, select an appropriate tool from the Add Tool group and
press the Add button

Adjusting the Location Tool Parameters

The location tool parameters are adjusted by adjusting the values of each parameter
in the General and settings pane.

Inspect Part

There are different Inspection tools in the ‘Add Tool’ Palette as shown above. To
add a tool to your job, select an appropriate tool from the Add Tool group and press
the Add button.We used measurement tools > Measure distance.

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If this distance is not within the range, the Cognex sends the signal to PLC that it is
a bad part.

Select a particular inspection tool. The Links tab allows a tool's output result to be
used as an input parameter to another tool. In the links tab, we can add properties
to the link by selecting the data types.

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The location tools and the inspection tool parameters

can be viewed in the result pane. TestRun provides a simple method to ensure that
their inspection settings are set appropriately. Analyzing parameter changes against
a user defined library of good and bad parts, TestRun identifies parameters that are
out of range.

3. Configure Results

Inputs

There are 2 general purpose direct (built-in) inputs in In-Sight 7000 series vision
system. Lines 2 and 3 are the input lines for the Direct I/O.

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Configuring a Discrete Input Line

 On the Sensor Menu, click Discrete I/O Settings.

 Click Input Settings.

 Click the I/O Module button to open the I/O Module Configuration dialog
and configure the I/O module. Once configured, press the OK button to
close the I/O Module Configuration dialog and return to the Discrete Input
Settings dialog.

Outputs

The direct (built-in) outputs in In-Sight 7000 series vision system are

 4 high-speed outputs

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 2 user-configurable LEDs (1 green, 1 red)

4. Finish

Fillmstrip

The filmstrip can be used to play back images recorded to the PC or review images
and results stored to the sensor.

Save Job

Using ‘Save Job’, the tool settings and the information specific to that job are
saved. Although job is saved during previous EasyBuilder steps, the Save Job step
serves as an important reminder. EasyBuilder provides no "automatic save"
capability, so any unsaved changes will be lost if power is cycled on the sensor.

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Run Job

Running a job on a sensor simply involves placing the sensor Online.

The image setup in the EasyBuilder interface is then organized and built in
Spreadsheet view as shown below.

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4.10 Process Flow Chart

Start

Load Part to Station

1

Activate Palm Button

Turn table Rotates

to next position

Station 2 Pick Place Station 3 press Cognex vision system

operation begins operation begins checks the part is OK
or NOT

NOT OK

OK
Station 4 press
operation
begins
Station 5 Robot
operation

Robot place part on

smart motor

Smart motor moves

the part

Operations 60
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4.11 Cycle Time Calculation:

The time required to process the parts at station 1 (ie part place is 8-10 sec)
and station 2 and station 3 is 3 sec each. The most time consuming station is the
robot pick and place which is about 11sec. This is one station which has variable
effect on part production.

Thus the total cycle time would be 25 seconds per part assembly. Since a
new case is assembled every 11 seconds (ie robot pick and place) after the first
cycle, the total production rate would be 325 Doodad cases per hour.

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5. OPERATOR MANUAL

5.1 Explanation of Set-Up

OPERATION
STAGE 1

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The operator loads the first piece of part into the lower nest and then manually he
closes the upper nest. After that he places the other piece of part on the upper nest.
Once the parts are loaded the operator press both the palm buttons so that the turn
table rotates. Now the part is in stage 2

STAGE 2

In stage 2 when the parts arrives in the station the vertical cylinder extends and
takes the upper part from the nest. As soon as the upper part is removed, the
horizontal cylinder extends and moves the upper nest. Then the vertical cylinder
places the part on the lower part.

STAGE 3

Once the parts are aligned in stage 2 the part moves to stage 3 for pressing
operation. In stage 3 the vertical cylinder extends slowly and presses the parts.

STAGE 4

Once the parts are pressed in stage 3 the turn table moves the part into stage 4.
Here in stage 4 we are using a vision system to check the accuracy of pressing
operation that has been done in stage 4. If the part is good then the table moves the
part to stage 5 or if it is bad part the vertical cylinder extends and press again so
that the parts gets aligned. Then it moves it to stage 5.

STAGE 5

Here when the part arrives two operations are carried out.

1) If the part is good, the robot picks it and places it on the smart motor which
takes it away to unload.
2) If it is a bad part, the robot picks it and places in the bad parts bin.

NOTE: Please make sure that the operator keeps his both hands on the palm
buttons in 500ms delay for proper operation.

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5.2 Step by Step Operating Procedure:

1. Check machine to make sure that everything is in place as required.
2. Make sure that E-STOP button is released.
3. Push RESET button to bring all parts of the machine to its home position.
4. Switch to AUTOMODE from HMI.
5. Push START (green) button.
6. Load lower nest in station 1 with a part.
7. Slide the upper nest properly aligned on the top of lower nest.
8. Second part is placed on the upper nest.
9. Activate the robot as per the HMI indication of good or bad part.
10.Press the two hand control palm button (cycle ACTIVATION buttons) to
start Auto Cycle.
11. Once the turn table rotates by one index repeat step 6-11.

5.3 Troubleshooting:

CONDITION REMEDY
a. Check input power.
Machine will not run
b. Check E-stop to ensure it is released.

a. Check if any part is misplaced. If so, check in which

E-stop fault station and take the parts out from that station.
b. Check if any cylinder is not extended or retracted
(Especially for new shift operators) properly. If so, go to manual mode in the HMI and
press RESET button.

Nest fault a. Press E-stop.

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b. Make sure the upper nest is properly aligned over

the lower nest at station 2.

a. Press E-stop.
b. Ensure airline is ON.
Air fault
c. Check if there is any air leakage (by noise). If so, call
technician.

Bad count fault

(occurs if 5 bad parts are produced a. Maintenance of the system is recommended.
continuously)

Linmot fault
a. Press RESET button on HMI and shut down and
(may occur due to overheat or over restart the system.
voltage)

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6. CONCLUSION

The project was successfully completed as expected. All systems are working as
per the requirements. Even though the project worked well there were some short
comings. It was difficult to integrate the robot and plc. There were no any
communication software or devices available to integrate the both. But somehow
we were able to operate the robot for the particular task and accompany it to work
well with the system. Similarly there were some draw back with the vision systems
but it wasn’t a barrier for the working of the system.

One of the major problem found was the HMI. It was difficult to establish the
connection with the HMI and plc. The manual for the HMI wasn’t self-
explanatory. Even though we were able to transfer the screens built in the software
to the HMI, it was not possible through the plc. It took a while for all group
members to understand the software used in the project but towards the end
everything worked as planned. Some new devices such as proximity sensor, relays
were added which improved the overall efficiency of the system. Overall the
outcome of the project was favorable.

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7. POSSIBLE IMPROVEMENTS TO THE

SYSTEM

 In this system, the rotational speed of the table is set as a constant value. To
improve the functionality of the system, it is good idea to include variable
speed for the rotation of the table. (So that the assembling process can be
slowed and accelerated on operator’s choice).

 The upper part holder in the table has only manual operation. Operator need
to move the upper part holder by hand. This part of the system can be
improved by giving an electric drive to move the upper part holder

 In order to improve the efficiency of the program, part sensors can be placed
at all stations so that feedback about the presence of part will be obtained.

 In the given system two press stations are present. It takes more space and
redundant. The second press can be removed and this place can be utilized
for the vision system components.

 The vision system in this project lacks suitable place for its operation. One
way to improve the vision system by removing the second press and placing
vision system at that place. Another way is to take the pictures of the
assembled part from top so that better images will be obtained for error
analysis.

 Indicators for good part and bad part can be given. For example, green light
for good part detection and red light for bad part detection.

 Safety feature of the system can be improved by including a light curtain in

the system.

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8. FUTURE SCOPE

The project involves the reverse-engineering of an already existing automated

work cell and reconfigure it to assemble Doodad Cases for G&G Automation.

In this project we can have the following upgrades in future.

 Adding a multimedia camera to see what is going inside the home by sitting
in office or somewhere

 Upgrading the palm buttons to a finger print touch button, so that the
machine can only be accessed by the corresponding operator

 Upgrading the vision system to a better one

 Can add a voice alarm, so that the machine can exactly tell the operator what
the problem is.

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9. APPENDICES

9.1 CX-Programmer Manual

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9.2 CX-Designer Manual

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9.3 Cognex Manual

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